Advanced floor mat

ABSTRACT

An advanced floor mat is disclosed. In an embodiment of the present invention, the floor mat includes a cleanable portion. The floor mat may also include a water dissipation component, a water absorbing component, a cushioning component, customized graphics, a transparent cleanable portion, a tacky surface on the cleanable portion, an antibacterial composition, an antifungal composition, and a fragrance. The cleanable portion may be erodible and may include a plurality of cleanable reusable layers. If a tacky surface is included in the floor mat, an anti-slip feature may be associated with the tacky surface to help prevent slipping on a possibly wet tacky surface. Additionally, a sensor system may be included in the floor mat to assist a user in identifying when the floor mat may require cleaning.

[0001] This application claims the benefit under 35 USC section 119(e)of U.S. provisional application 60/227,596, filed Aug. 25, 2000.Further, this application is a continuation-in-part of internationalapplication no. PCT/US00/30206, filed Nov. 2, 2000, which is acontinuation-in-part of U.S. application Ser. No. 09/553,234, filed Apr.19, 2000 and issued May 22, 2001 as U.S. Pat. No. 6,233,776. ApplicationSer. No. 09/553,234 is a continuation-in-part of U.S. application Ser.No. 09/418,752, filed Oct. 15, 1999, which is a continuation-in-part ofU.S. application Ser. No. 09/304,051, filed May 4, 1999 and issued Apr.24, 2001 as U.S. Pat. No. 6,219,876.

BACKGROUND AND DISCUSSION OF THE INVENTION

[0002] The present invention relates to a floor mat. More specifically,the invention provides a floor mat that includes a cleanable portion.The floor mat may also include a water dissipation component, a waterabsorbing component, a cushioning component, customized graphics, atransparent cleanable portion, a tacky surface on the cleanable portion,an antibacterial composition, an antifungal composition, and afragrance. The cleanable portion may be erodible and may include aplurality of cleanable reusable layers. If a tacky surface is includedin the floor mat, an anti-slip feature may be associated with the tackysurface to help prevent slipping on a possibly wet tacky surface.Additionally, a sensor system may be included in the floor mat to assista user in identifying when the floor mat may require cleaning.

[0003] Floor mats are known for cleaning the soles of a person's shoeswho is about to enter a particular area or room. One problem with floormats in general is how to keep the floor mat sufficiently clean suchthat it may perform its function of cleaning the person's shoes when, byits very nature, it is purposefully dirtied when performing itsfunction.

[0004] Known floor mats may be comprised of a single, unitary piece ofmaterial. Whereas these single structure floor mats may be kept cleanby, for example, washing the floor mat, it may be required that theentire floor mat be removed from its location for washing and thus, thefloor mat is not available where desired while the entire mat is beingcleaned. Alternatively, even if the mat can be cleaned in-place, whichmay not be a possibility if it is located in, for example, a carpetedarea, it may be inconvenient to clean the mat in-place.

[0005] U.S. Pat. No. 3,785,102 to Amos discloses a throw-away padcomprising a plurality of stacked disposable sheets where, when aparticular sheet is dirtied, the dirty sheet is removed and disposed of.The next sheet that is exposed after the dirty sheet is discarded isclean and thus, a clean surface is again available. However, there maybe problems with comprising the floor mat of disposable sheets.Disposing of each dirty sheet may be uneconomical since each sheet isdiscarded after it becomes dirty. Additionally, after some finite numberof sheets are disposed of, no sheets will remain and thus no effectivecleaning surface is available.

[0006] U.S. Pat. No. 3,785,102 to Amos also discloses that an adhesivecan be provided on each sheet's top surface to improve its ability toremove dirt from a person's shoes. However, again, these sheets are notcleanable and therefore are not reusable.

[0007] U.S. Pat. No. 3,717,897 to Amos et al. discloses a pad forcleaning shoes and wheels. The pad includes a thin water-washableadhesive covering its upper surface for removing dirt from shoes andwheels. Whereas the '897 patent discloses a pad with a water-washableadhesive upper surface, the pad is not known for use in domestic oroffice-type applications. As stated in the '897 patent, the pad isplaced at an entrance doorway leading into a clean room.

[0008] Tacky floor mats are by far more popular for utilization inindoor environments that are far removed from exterior outsideentrances, such as for clean rooms that are well-within the interior ofthe building in which they are used, e.g., hospital rooms, computer chipmanufacturing spaces, and gymnasiums. Thus, tacky floor mats are notknown for use in areas that are adjacent to entrances that lead from theoutdoor environment for cleaning the soles of a person's shoes prior toentry into the interior of a building, such as for example in an entryfoyer or on an outdoor porch.

[0009] Tacky floor mats are not known for use in domestic or office-typeapplications, e.g., home or business office use, because of severalknown deficiencies. One of these deficiencies is that their tackysurface will not be as effective if it becomes wet. Therefore, if thetacky surface floor mat was utilized in an outdoor environment, such asthe outdoor porch mentioned above, or in an indoor environment that isadjacent to or near an outdoor entrance, such as an entry foyer of ahome or business, for cleaning a person's shoes prior to furtherentering the home or business, the mat is likely to become wet andtherefore not effective. The mat could become wet from, for example, themoisture in the atmosphere or from moisture carried on the soles of theperson's shoes who steps on the mat. Additionally, if the tacky surfacebecomes wet it may become slippery and thus cause a hazard for theperson who steps on it.

[0010] Additional deficiencies with using known tacky floor mats forhome or office-type applications as discussed above is their likelihoodof becoming trip hazards and their lack of aesthetic appeal. In the '897patent, because the pad is designed for use in clean room environments,it is adhesively adhered to the passageway floor in front of theentrance doorway. This may be satisfactory for retaining the matin-place in clean room-type of applications, however, if it wasattempted to use the '897 pad on a carpeted floor, the pad would notproperly adhere to the carpet and thus a trip hazard would be present.This could result in significant liability issues. The '897 pad does nothave sufficient mass for it to remain in-place without utilizing anadhesive. Regarding aesthetics, because tacky floor mats are known onlyfor their functional characteristics, and thus for use only in “cleanroom”-type applications, they are not aesthetically pleasing. Therefore,for at least the above reasons, tacky floor mats are not known for usein home or office-type applications.

[0011] Additional drawbacks with known floor mats exist that aredirected to issues of customization for a particular purchaser and alack of additional cleaning properties. A floor mat may be the firstobject that a visitor to a particular home or business encounters. Assuch, the owner of the home or business may want to utilize the floormat to graphically convey an initial greeting or message to the visitor.Whereas floor mats are known that may include a greeting on them, it isnot currently known to allow for a particular purchaser to customize thedisplayed graphic so that the message is tailored to convey a particularmessage desired by the purchaser. For example, on Halloween thepurchaser may want the floor mat to display a “Happy Halloween” message.In another situation, the purchaser may want to greet a particularvisitor with a message such as “Hello, Joe”. Currently, it is not knownto provide a floor mat where an individual can customize the floor matto display a particular message that they want to convey and in certaincircumstances even change the floor mat's message they want to convey.

[0012] An additional problem with known floor mats, as mentioned above,is that they are limited in their ability to clean the soles of aperson's shoes. Whereas known floor mats may be capable of removing dirtparticles from the shoe's soles, they are not able to disinfect thesoles nor provide a scent to the soles to assist in masking anyunpleasant odors that may be associated with the shoes.

[0013] An additional drawback with known floor mats, even if they arecleanable, is that they do not assist a user in determining when thefloor mat may require cleaning. Generally, the owner or custodian of thefloor mat does not continuously or regularly monitor the condition ofthe floor mat with respect to cleanliness. Therefore, the floor matcould require cleaning, and because the owner is not consciouslymonitoring the condition of the floor mat, there could be a significantperiod of time before the owner realizes that the floor mat requirescleaning. Therefore, it would be desirable to assist the owner/custodianof the floor mat in determining when the floor mat requires cleaning.

[0014] Therefore, it would be desirable to provide an advanced floor matthat could address deficiencies that exist with currently known floormats. The advanced floor mat of the present invention overcomesdeficiencies in the prior art and may include a base portion whichincorporates a cleanable portion that is adapted to be removablyreceived within the floor mat. The floor mat may also include featuressuch as a water dissipation capability, a water absorbing capability, acushioning capability, customized graphics, a transparent portion, atacky surface on the cleanable portion, an antibacterial composition, anantifungal composition, and a fragrance. The cleanable portion mayinclude the features of being erodible and containing a plurality ofcleanable reusable layers. If a tacky surface is included in the floormat, an anti-slip feature may be associated with the tacky surface tohelp prevent slipping on a possibly wet tacky surface. Additionally, asensor system may be included in the floor mat to assist a user inidentifying when the floor mat may require cleaning. Other features willbe apparent from the detailed description which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The various features of the invention will best be appreciated bysimultaneous reference to the description which follows and theaccompanying drawings, in which:

[0016]FIG. 1 is a perspective view of a floor mat in accordance with anembodiment of the present invention;

[0017]FIG. 2 is an exploded perspective view of the floor mat of FIG. 1;

[0018]FIG. 3 is an exploded side view of an alternative embodiment ofthe floor mat of the present invention;

[0019]FIG. 4 is an exploded side view of an alternative embodiment ofthe floor mat of the present invention;

[0020]FIG. 5 illustrates a third alternative embodiment for a tackyinsert portion with an anti-slip feature for the floor mat of thepresent invention;

[0021]FIG. 6 illustrates a fourth alternative embodiment for a tackyinsert portion with an anti-slip feature for the floor mat of thepresent invention;

[0022]FIG. 7 is a side view of the embodiment for the tacky insertportion with an anti-slip feature of FIG. 6;

[0023]FIG. 8 is a perspective view of a fifth embodiment for a tackyinsert portion with an anti-slip feature for the floor mat of thepresent invention;

[0024]FIG. 9 illustrates a sixth alternative embodiment for a tackyinsert portion with an anti-slip feature for the floor mat of thepresent invention;

[0025]FIG. 10 illustrates the tacky insert portion with an anti-slipfeature of FIG. 9 in conjunction with an alternative embodiment for thebase portion;

[0026]FIG. 11 illustrates a seventh alternative embodiment for a tackyinsert portion with an anti-slip feature and a water dissipatingcapability for the floor mat of the present invention;

[0027]FIG. 12 illustrates an alternative embodiment for a tacky insertportion and base portion with a water dissipating capability for thefloor mat of the present invention;

[0028]FIG. 13 illustrates a sensor system that may be utilized in anembodiment of the present invention;

[0029]FIG. 14 is an embodiment for a floor mat where the tacky portionand the non-tacky portion are separable;

[0030]FIG. 15 is a perspective view of an embodiment of the floor mat ofthe present invention as being used in one step of a process forutilizing the floor mat;

[0031]FIG. 16 is a perspective view of the floor mat of FIG. 15 as beingused in a second step of a process for utilizing the floor mat;

[0032]FIG. 17 illustrates an alternative embodiment for a floor mat inaccordance with the present invention that includes interchangeable baseportions;

[0033]FIG. 18 illustrates an alternative embodiment for a floor mat inaccordance with the present invention that includes single sheets forthe cleanable portion;

[0034]FIG. 19 illustrates a roll of sheets that may be utilized with theembodiment of FIG. 18;

[0035]FIG. 20 illustrates a storage container that may be utilized withthe roll of sheets of FIG. 19;

[0036]FIG. 21 illustrates an alternative embodiment for a floor mat inaccordance with the present invention that includes a scraper movable ontracks;

[0037]FIG. 22 illustrates an alternative embodiment for a floor mat inaccordance with the present invention that includes a scraper movable ontracks;

[0038]FIG. 23 is an exploded view of a floor mat according to anembodiment of the invention;

[0039]FIG. 24A illustrates a separable section of a non-tacky layer ofthe floor mat, with snap fasteners for fastening the separable sectionto a base portion underlayer of the floor mat;

[0040]FIG. 24B illustrates a separable section of a non-tacky layer ofthe floor mat, with hook-and-loop fasteners for fastening the separablesection to a base portion underlayer of the floor mat;

[0041]FIG. 24C shows one possible configuration for a remove tab of atacky insert of the floor mat;

[0042]FIGS. 24D and 24E are side elevation views of a plurality ofremove tabs according to two different possible arrangements;

[0043]FIG. 25 is a perspective view of a floor mat according to yetanother embodiment of the invention, wherein a non-tacky layer isco-extensive with a base portion underlayer;

[0044]FIG. 26A shows two possible embodiments for an adhesiveundersurface of a tacky insert;

[0045]FIGS. 26B-26D show a possible embodiment of a tacky insert and abase portion underlayer according to the invention, wherein the tackyinsert has notches for aligning with protrusions' on the base portionunderlayer;

[0046]FIG. 27A shows details of layers in one possible embodiment of amulti-layer tacky insert;

[0047]FIGS. 27B and 27C shows anti-slip material interspersed withadhesive on a layer of a tacky insert, according to one possibleembodiment;

[0048]FIG. 28 illustrates three alternative process flows formanufacturing tacky inserts according to the invention;

[0049]FIGS. 29A-29C show alternative configurations of an apparatus formanufacturing tacky inserts according to the processes illustrated inFIG. 28;

[0050]FIG. 30 shows details a rotary die cutter such as could be used inthe processes described in FIGS. 28 and 29A-29C;

[0051]FIGS. 31A-31D show alternative embodiments of tacky inserts,wherein the tacky inserts have apertures configured to receive nodularanti-slip components; and

[0052]FIGS. 32A-32E show possible embodiments of nodular anti-slipcomponents.

DETAILED DESCRIPTION

[0053]FIG. 1 illustrates a first embodiment for a floor mat 100 inaccordance with the principles of the present invention. As can be seenin FIG. 1, floor mat 100 includes a base portion 200 and a cleanableinsert portion 300. As will be further described later in thisspecification, in this embodiment, cleanable portion 300 is receivedwithin base portion 200 and is removable from base portion 200.

[0054]FIG. 2 illustrates an exploded, perspective view of the floor matof FIG. 1. As can be seen in FIG. 2, base portion 200 is formed as agenerally flat, planar member and defines a recess 210 within the topsurface of base portion 200. Base portion 200 provides sufficient weightand mass for supporting cleanable insert portion 300 and maintaining thefloor mat's positioning on the surface on which it is placed. Baseportion 200 may include, as will be discussed below, a water dissipationcapability, a water absorption capability, and a cushioning capabilityand may be comprised of materials such as polyurethane, polyisoprene andother cross-linked elastomeric materials, such as nylon-6, molded orwoven to form a porous structure. Recess 210 can be configured in any ofa variety of geometric configurations, however, in the presentembodiment, recess 210 is configured in a rectangular shape. Recess 210has a length L₁ and a width W₁. The depth of recess 210 is such that itis able to receive within it cleanable insert portion 300 such that whencleanable insert portion 300 is received within recess 210, the topsurface of cleanable insert portion 300 lies generally in the same planeas the top surface of base portion 200.

[0055] The top surface of base portion 200 may be colored with any colordepending upon the desires of a particular purchaser, however, it ispreferable that a color be utilized that will minimize the visibility ofany dirt that is accumulated by base portion 200. For example, it may bedesirable that darker colors be utilized for the top surface of baseportion 200 rather than lighter colors. However, again, any particularcolor may be utilized for base portion 200, and particularly the topsurface of base portion 200, depending upon the particular desires of anindividual. Additionally, the base portion 200 may be either translucentor opaque.

[0056] As can be seen in FIG. 2, the surface of base portion 200 whichdefines the bottom of recess 210 may include graphics 220 on thatsurface. In the illustrated embodiment, the graphics include pictorialrepresentations of flowers and a text message which spells out the word“WELCOME”. The present invention is not limited to any particulargraphic within recess 210 and the present invention may include any of avariety of different forms of graphics.

[0057] Graphics 220 may be modified, and thus customized, by anindividual after the floor mat has been purchased by the owner. Theowner may customize the mat at their home or office and, thus, a graphicthat may be appropriate for a particular situation may be modified bythe individual for display in another situation. For example, thegraphic may display a message stating “Happy Halloween” for Halloweenand may be modified to display “Happy Holidays” during the winterholiday season. Thus, as can be understood, the graphics are modifiableby a user and thus, may be customized for the particular desires of aparticular user.

[0058] As stated above, the present invention is not limited to anyparticular form for graphics 220. The graphics 220 can be customized bya user to include any of a variety of different colors, pictures,messages, or other representations that the user may want to display. Inaddition, the visible intensity of a color(s) can be modified. Forexample, a color that glows at night could be included in graphics 220for an occasion such as Halloween.

[0059] Any of a variety of different types of structures or methods maybe practiced in the present invention for modifying graphics 220 offloor mat 100 and the present invention is not limited to any particularmethodology or structure for modifying graphics 220. Additionally, allof the various embodiments contemplated for providing a modifiablegraphic display in the floor mat of the present invention can beincorporated in either, or both, of the base portion or the insertportion. For example, the graphics may consist of pre-formed messages orart forms which may be adhered to either the surface which defines thebottom of recess 210, such as by using an adhesive or fastener assembly,e.g., a hook and loop assembly, or to the underside of insert portion300 such that, when insert portion 300 is placed within base portion200, the graphics would be visible through a transparent insert portion.

[0060] Alternatively, a variety of different graphics may be storedwithin floor mat 100 such that a user is able to selectively uncover aparticular graphic for display while the other available graphics remaincovered within floor mat 100. This type of selectability is known inother mediums where selectivity between a variety of different graphicswithin a common display panel is desired. For example, advertisingbulletin boards at sporting events are able to selectively display afirst particular message during a first particular period of time anddisplay a second message during a second period of time on the samebulletin board.

[0061] A third possible alternative is to provide a modifiable displayon the floor mat. The display surface can be associated with either thebase portion or the insert portion, e.g., on either the bottom surfaceof recess 210 or attached to the bottom of insert portion 300. A displaycould be included on the front of the floor mat, on the back of the matsuch that it is viewable through a transparent portion of the mat,embedded in the mat, attached to the mat, or integrally formed in themat. For example, the display could be comprised of a small, thin box ofgraphics that could attach to a tacky portion and/or a base portion orany other component part of the floor mat. However it is associated withthe floor mat, a user may design and display their customized graphicand may subsequently modify that graphic such that it is replaced withanother graphic. A display surface such as an erasable writing boardcould be utilized for this purpose.

[0062] It is also contemplated that a modifiable electronic displaysurface could be provided, such as, for example, a liquid crystaldisplay. The display could be connected to a computer and a computergenerated image could be displayed on the display. Thus, the imagedisplayed on the display could be modified by generating a differentcomputer image and displaying that computer image on the display. Thedisplay could be associated with base portion 200, such as includedwithin recess 210, or could be included on a bottom surface, facingupward, of insert portion 300. Alternatively, the display could beintegrally formed with either of the base portion or the insert portion.The modifiable display could utilize a plurality of different graphicsthat can be displayed in any of a variety of manners on the display. Forexample, the graphics could be displayed in a generally fixed positionon the display or could scroll across the display, with both exemplarymethodologies displaying multiple graphics either individually or incombination.

[0063] Other alternatives for modifying the graphics 220 of floor mat100 include using light emitting polymers to create, and thus change,graphics 220. The light emitting polymers can be either applied to,attached to, or woven into the floor mat. The light emitting polymersmay be utilized on any portion of floor mat 100, for example, on eitherthe base portion- or the insert portion, or on any other portion of thedifferent embodiments for the floor mat. Light emitting polymers areknown and described in U.S. Pat. Nos. 5,945,502, 5,869,350, and5,571,626, which are incorporated herein by reference in their entirety.

[0064] Other options for a display are to use electronic ink or electricpaper. Electric paper is available from Xerox and is described in U.S.Pat. Nos. 5,723,204, 5,604,027, 4,126,854, and 4,143,103, which areincorporated herein by reference in their entirety. Electric paperemploys thousands of tiny, electrically charged beads, called Gyricon,each about the width of a human hair, to create pixels. The two-tonebeads are embedded inside a liquid-filled plastic sheeting that formsthe surface of the paper. Each bead, half-black, half-white, gyrates inresponse to an electric field. Whether the beads are black- orwhite-side up determines the image. Because there's no need to refreshthe image, and because the screen isn't backlit, electric paper usesonly a fraction of the power used by conventional electronic displays.Electromagnetic styluses and printer-like devices can be used forgetting images onto the paper.

[0065] Electronic ink is available from E Ink Corp., at 45 Spinelli Pl.,Cambridge, Mass. 02138. Electronic ink uses a microencapsulatedmicromechanical display system. Tiny microcapsules are captured betweentwo sheets of plastic to create pixels. Alternatively, the capsules maybe sprayed on a surface. The result is a flexible display material. Thetiny capsules are transparent and contain a mixture of dark ink andwhite paint chips. An electric charge is passed through the capsules.Depending on the electrostatic charge, the paint chips float at the topor rest on the bottom of each capsule. When the paint chips float at thetop, the surface appears white. When they rest at the bottom, and thusunder the ink, the surface appears black. Each of the two states isstable: black or white. A transparent electromagnetic grid laid over thesheet's surface controls the shape of the image. The display may bewirelessly connected to, for example, a computer and thus, the WorldWide Web by utilizing, for example, a Motorola paging system. Text onall displays, if multiple displays are used, can be changed at once by asingle editor, through a Web page.

[0066] Again, a display, which could utilize any of the methodsdiscussed above for modifying the display, could be associated with anyportion of the floor mat, such as base portion 200 within recess 210 oron a bottom surface, facing upward, of insert portion 300.Alternatively, the display could be integrally formed with either of thebase portion or the insert portion. The display could be utilized in anyof the embodiments disclosed herein for the floor mat of the presentinvention, including a floor mat that includes a tacky surface and anon-tacky floor mat embodiment.

[0067] In further describing base portion 200, as mentioned above, baseportion 200 may also include both a water dissipation component and acushioning component. The water dissipation component provides fortransferring moisture from the soles of a person's shoes that isstanding on floor mat 100 to reduce the degree of moisture transferredto cleanable insert portion 300 and the cushioning component providesfor conforming the floor mat 100 to the shape of the person's soles suchthat a greater amount of the debris on the person's soles may be removedby floor mat 100. The present invention is not limited to any particularstructure or material for the water dissipation component and thecushioning component. For example, the water dissipation component maybe comprised of any of a wide variety of known materials, such aspolyamides, vinylics, and polyisoprene. It is desirable, but notrequired, that the water dissipation component dissipate or move thewater and not retain the water. Thus, porous materials, and nothydrophilic materials, are desired. The cushioning component may becomprised of any of a variety of cushioning components to include, forexample, foam rubber.

[0068]FIG. 2 also further illustrates cleanable insert portion 300. Ascan be seen, cleanable insert portion 300 has a geometric shape which iscomplementary in size and form to the recess 210 that is formed withinbase portion 200. As such, cleanable insert portion 300 is able to bereceived securely within recess 210. Thus, cleanable insert portion 300has a length L₂ which is just slightly smaller than the length L₁ ofrecess 210. Likewise, cleanable insert portion 300 has a width W₂ whichis also just slightly smaller than width W₁ of recess 210.

[0069] On the bottom side 310 of cleanable insert portion 300, i.e.,that surface which contacts the surface which defines the bottom ofrecess 210, an attachment mechanism may be provided such that cleanableinsert portion 300 may be removably attached to base portion 200 withinrecess 210. Any of a variety of different attachment mechanisms may beprovided on the bottom surface of cleanable insert portion 300 toinclude, for example, a hook and loop fastener assembly or an adhesive.Regardless of the particular securement mechanism used to removablyattach cleanable insert portion 300 to base portion 200, in thisembodiment, cleanable insert portion 300 may be removed from baseportion 200 such that it may be cleaned by a user and, after cleaning,be reinserted within recess 210 such that a clean surface is nowprovided for floor mat 100.

[0070] As stated above, cleanable insert portion 300 may be formed froma transparent material such as hydrophilic aliphatic acrylic polymersand copolymers incorporating acrylic acid, hydroxy ethyl methacrylate,and glycerin monomethacrylate. Forming cleanable insert portion 300 of atransparent material would allow an individual to view the customizedgraphics that may be provided within floor mat 100, as discussedpreviously. Alternatively, the insert portion 300 could be opaque.

[0071] Additionally, the top side of cleanable insert portion 300 mayinclude a tacky surface. The tacky surface would provide for assistingin removing debris from the soles of a person's shoes that is standingon cleanable insert portion 300. When the top tacky surface of cleanableinsert portion 300 is dirtied to such an extent that the user desires toclean insert portion 300, in this embodiment, the user removes insertportion 300 from base portion 200 and cleans insert portion 300 toremove the accumulated debris. The insert portion 300 is then reinsertedinto base portion 200.

[0072] The tacky surface that is provided on the top side of cleanableinsert portion 300 could be comprised of any of a variety of materials,such as polyvinyl chlorides combined with a suitable plasticizer,plasticized neoprene, polysulfides, and polyurethanes. Additionally,acrylics, such as butyl acrylate and many of its homologues, may beutilized. Again, the present invention is not limited to any particularmaterial. The tacky surface may be formed, generally, from any adhesivematerial. The only consideration, in this embodiment, is that thesurface should maintain its tacky characteristic even after repeatedcleaning cycles.

[0073] The present invention is not limited to any particularmethodology for cleaning insert portion 300. Insert portion 300 may becleaned by any of a variety of methods depending upon a particularmaterial composition for insert portion 300. For example, insert portion300 may be cleaned by placing insert portion within a washing machineand washing insert portion 300 or insert portion 300 may be cleaned byscrubbing insert portion 300 with a scrub brush and soap and water orwith a cleaning agent such as “Spic 'N Span”.

[0074] Additionally, the insert portion 300 could be cleaned byutilizing a roller that also includes a tacky surface around thecircumference of the roller. The tacky surface of the roller iscomprised of a stronger adhesive than that of the tacky insert portionsuch that, as the tacky surface of the roller is rolled over the tackysurface of the insert portion, any dirt and debris on the tacky insertportion will be drawn off of the tacky insert portion and will adhere tothe roller. In this manner, a roller with a tacky surface could beutilized to clean the tacky insert portion.

[0075] Again, however, the present invention is not limited to anyparticular methodology or cleaning agent for cleaning insert portion 300and any cleaning methodology or agent compatible with the composition ofinsert portion 300 is contemplated.

[0076] Floor mat 100 may also include additional features for assistingin the cleaning of the soles of a person standing on floor mat 100. Forexample, base portion 200 and/or insert portion 300 may include anantibacterial composition and an antifingal composition. Antibacterialcompositions such as anthraquinone derivatives of polyethylene glycolmono- and di-methacrylate could be utilized. Thus, floor mat 100 wouldbe bactericidal. The antibacterial feature would be particularlydesirable because the floor mat would be able to both clean structuraldebris from the soles of the person's shoes and remove any potentiallyharmful bacteria from the person's soles as well.

[0077] Additionally, in order to further provide for a desirable solesurface prior to entering a particular area, floor mat 100 could also beprovided with a fragrance. Flavones such as tricyclic molecules witharomatic substitution or organic ethers, e.g., liminolic acid, could beutilized. The fragrance is transferred from floor mat 100 to the solesof the person's shoes such that any undesirable odors are favorablymasked by the fragrance.

[0078] The present invention is not only limited to utilizing anantibacterial composition, an antifungal composition, and/or a fragrancein floor mat 100. Rather, floor mat 100 could also incorporate a varietyof other substances that would assist in cleaning the soles of aperson's shoes.

[0079] Any variety of structures or methods could be utilized forassociating an antibacterial composition, an antifungal composition, afragrance, or any other composition, with floor mat 100. The substancescould be applied as releasable, or dissipatable, coatings to floor mat100 or could be releasably embedded as, for example, pellets within thestructure of floor mat 100 such that as pressure is applied to floor mat100 the substances are dispensed to the soles of the person's shoes.

[0080]FIG. 3 illustrates an alternative embodiment for floor mat 100. InFIG. 3, it is illustrated that base portion 200 may include separatelayers for a water dissipation component 230 and a cushioning component240. Water dissipation component 230, in this embodiment, is disposed ona top side of the cushioning component 240. However, the presentinvention is not limited to this particular embodiment for waterdissipation component 230 and cushioning component 240. For example, asingle hybrid structure could be utilized for base portion 200 thatwould include the material properties to provide for both waterdissipation and conforming structure.

[0081] Alternatively, FIG. 4 illustrates that the floor mat may includeboth a water dissipation component, or wicking layer, and a waterabsorbtion layer. In FIG. 4, floor mat 400 includes wicking layer 410and water absorption layer 420. The wicking layer 410 could be comprisedof polypropeline or olefins, or any other suitable material that has theproperties of moving the water from the surface of floor mat 400. Thewater absorption layer 420 is disposed underneath the wicking layer 410and absorbs any water that passes through the wicking layer 410. Thewater absorption layer 420 could be periodically removed and dried, suchas by example only, in a drying machine.

[0082] Of course, a wicking layer 410 may be used either with or withouta water absorption layer 420 and a cushioning layer, as describedpreviously in other embodiments, and the water absorption layer 420could be used with or without a wicking layer 410 and a cushioninglayer. Additionally, both the wicking layer and/or the absorption layerand/or the cushioning layer could be used with or without a tackyportion.

[0083] Returning to FIG. 3, FIG. 3 also illustrates an alternativeembodiment for insert portion 300. Whereas the previously disclosedembodiment for insert portion 300 was discussed as a single structuralmember that could include a tacky surface on a top side thereof, theembodiment of FIG. 3 for insert portion 300 is comprised of a pluralityof layers. As can be seen, layers 301-305, comprise insert portion 300.Each of the layers may include a tacky surface on a top side thereof, aswas described previously for insert portion 300. In use, a top-mostlayer, e.g., layer 301, may be removed from its adjacent lower layer,e.g., layer 302, and may be independently cleaned. After cleaning, thelayer may be reinstalled within recess 210 on top of the exposed layerof insert portion 300. In this manner, insert portion 300 may be cleanedby removing a top-most layer, cleaning that layer, and reinstalling thatlayer within recess 210. Whereas each layer is described as beingindependently cleanable, it is not required that each individual layerbe cleanable. Each layer may be formed of materials as describedpreviously when discussing the embodiment of FIGS. 1 and 2 for theinsert portion.

[0084] Other alternative embodiments for insert portion 300 arecontemplated. For example, whereas the previously disclosed embodimentsdiscussed insert portion 300 as being comprised of one or more layerswith a tacky surface on a top side of the layer(s), it is not requiredthat insert portion 300 be formed with only a tacky surface on a topside thereof. More specifically, an alternative embodiment for insertportion 300 could include forming insert portion 300 as a singlestructural member from a material which is tacky in compositionthroughout the entire cross-section of the material. A material such asa blend of a noncross-linked hydrophilic thermoplastic, preferably apolyethylene glycol diacrylate with n not exceeding 15, and ahydrophobic material, such as a polyvinyl neoprene chloride, could beutilized for the insert portion of this embodiment. By forming insertportion 300 from a uniform, tacky material, the insert portion 300 doesnot necessarily have to be removed from recess 210 of base portion 200to be cleaned. Insert portion 300 could be cleaned in this alternativeembodiment by eroding the top surface of the insert portion as a resultof use of the insert portion. Thus, by providing an erodible insertportion, the insert portion may be cleaned by the erosion of its topsurface as the insert portion is used within floor mat 100.

[0085] As insert portion 300 erodes, the exposed surface of insertportion 300 continues to be tacky in composition because of its uniformcross-section. As the exposed tacky surface erodes, the dirt captured bythe exposed tacky surface will dissipate as a result of the erosion andthus, the erosion of the insert portion itself provides for a cleanableinsert portion.

[0086] Alternatively, even with a uniform cross-section of a tackysubstance for insert portion 300, the user may remove insert portion 300from recess 210 and separately clean insert portion 300. Thus, the useris not required to rely solely on the erodible characteristic of insertportion 300 for cleaning of insert portion 300; rather, the user mayutilize the erodible cleaning feature of the insert portion incombination with a separate cleaning step of removing the insert portionfrom the base portion and independently cleaning the insert portion.

[0087] As discussed above, insert portion 300 may be comprised of avariety of materials, including materials such as tacky plastics, paper,or adhesives that can be cleanable and may or may not be erodible andreusable. If paper is utilized, the insert portion may be formed as asingle structural member or as a plurality of layers, as discussedpreviously. Additionally, the paper may include a tacky surface on atop-side thereof. The paper may be translucent, opaque, or colored, andmay include a graphic display thereon.

[0088] As discussed earlier, it is desirable, but not required, that thefloor mat contain a water dissipation and/or absorption capability. Thiscapability is desired to help prevent the tacky surface of the insertportion from becoming excessively wet and, thus, slippery. Whereas ithas been discussed that, in order to help prevent a user from slippingon the tacky surface of the insert portion, a water dissipation and/orabsorbing capability could be included in the floor mat to reduce thedegree of moisture on the tacky surface, this is not the only structurecontemplated for preventing the tacky insert portion from becomingslippery. Alternatively, the tacky insert portion itself could be formedto help prevent slipping. FIGS. 5-12 illustrate alternative embodimentsfor tacky insert portion 300. FIG. 5 illustrates tacky insert portion300 as including a grid pattern 320 of channels 322 that could becomprised of a non-tacky material. The channels could be either raisedfrom the surface of insert portion 300 or could lie co-planar with thetop surface of the insert portion. By forming the channels of anon-tacky material, even if the tacky material of insert portion 300became wet, a user would be assisted in not slipping on the slippery,wet tacky surface of the insert portion by the presence of the non-tackysurfaces which do not become slippery when wet.

[0089]FIGS. 6 and 7 illustrate another alternative embodiment for tackyinsert portion 300 which includes anti-slip particles 324, e.g., siliconor sand particles, which extend above the top surface 330 of the tackyinsert portion. It is desirable that the anti-slip particles becomprised of a material that does not become slippery when wet and thatthey be exposed from the tacky surface, however, it is not required.Even if the anti-slip particles are embedded within the tacky surface,their extension above the top surface 330 of the tacky insert portionwill provide a physical frictional restraint against slipping for thesoles of a person's shoes who is standing on the floor mat.

[0090] Whereas FIG. 5 illustrates tacky insert portion 300 as includinga grid pattern 320 of channels 322 that could be comprised of anon-tacky material and FIGS. 6 and 7 illustrate another alternativeembodiment for tacky insert portion 300 which includes anti-slipparticles 324 which extend above the top surface 330 of the tacky insertportion, it is not required that these two alternative embodimentscontain features that are mutually exclusive. For example, it iscontemplated that tacky insert portion 300 could include both a gridpattern of non-tacky channels and anti-slip particles, which is notillustrated specifically in the Figures but which can be easilyunderstood.

[0091] Another alternative for providing a slip-resistant tacky portionis to include a plurality of anti-slip members, or treads or nipples,that extend up through and slightly above the surface of the tackyportion. As can be seen in FIG. 8, in this embodiment, tacky portion 300is inserted within a base portion, which may be a water absorbent border500, and includes a plurality of apertures 342 within it. Each of aplurality of treads 344, which may extend upward from a base disposedunderneath tacky portion 300, extend up through one of the plurality ofapertures 342. A top-most end of each tread extends above a top-mostsurface 340 of tacky portion 300. As a person steps onto tacky portion300, the quantity and positioning of the treads 344 is such that thetacky portion is able to remove debris from the person's shoes and thetreads 344, at least one of which is stepped upon by the person,prevents slipping of the person on the tacky portion 300 should thetacky portion 300 become slippery when wet. The treads 344 may compresswhen stepped upon such that the top-most end of the tread is co-planarwith the top-most surface 340 of the tacky portion 300. In this manner,the tread will contact the person's shoes to prevent slipping but yetnot hinder contact between the person's shoes and the tacky surface ofthe mat, which enhances the cleaning of the person's shoes. Therefore,there is a relationship between the distance that the tread extendsabove the top-most surface of the tacky portion and the compressibilityof the tread; a relationship which provides the functionality discussedabove.

[0092] The treads may be configured in any shape and size. Additionally,the treads may be comprised of any material which is slip-resistant whenwet, such as, for example, rubber or plastics. The treads may includegrooves within them to further assist in preventing a person fromslipping on the tacky portion.

[0093]FIGS. 9 and 10 illustrate additional alternative embodiments forboth the tacky insert portion 300 and the base portion 200 that help toprevent slipping on a potentially wet tacky portion. As can be seen inFIG. 9, and as discussed previously, tacky insert portion 300 iscomprised of a plurality of layers 301, 302, and 303. Whereas only threelayers are illustrated, it can be understood that any number of layerscan be utilized in the present invention. As can be seen, tacky layers301-303 each contain a plurality of integrally formed raised portions300A. These raised portions can help to prevent a person from slippingon the tacky portion by providing increased friction between the topsurface of the tacky layer, due to the raised portions, and the person'sshoes. Thus, these raised portions can substantially reduce thepotential for slipping on the tacky portion if it becomes wet.

[0094] The raised portion 300A can be formed in each layer in a varietyof ways and the present invention is not limited to any particularmethod. One method for forming the raised portions is to assemble thelayers into a pad of layers and then insert the entire pad into amachine press. One face of the press is flat and the other face, i.e.,that face that is facing the non-tacky, or underside, of the layers,contains an array of bosses or bumps. When the pad is pressed in themachine press, all of the tacky layers become embossed with the patternon the press face, causing the raised portions, or embossed portions, ineach tacky layer of the pad. Thus, each embossed portion is integrallyformed in each layer and is comprised of an indentation on theunderside, or non-tacky side, of each layer and a raised portion on theupperside, or tacky side, of each layer.

[0095] As can be understood, in the method as described above forforming the raised portions, the raised portions of each layer arealigned with the raised portions of each other layer. It is desirable,but not required, that the raised portions of each layer are aligned sothat their shape may be easily maintained when the layers are stackedone upon another.

[0096] As can be seen in FIG. 10, base portion 200 may also be formed tobe complementary to the embossed layers. The surface 200A that defines abottom of the recess of base portion 200, which receives within it thetacky layers 300, can be formed with raised portions 200B. These raisedportions are positioned so that they are aligned with the raisedportions in the tacky layers. Thus, the raised portions 200B on surface200A are positioned within the indentations in the lower-most tackylayer when the layers are inserted into the recess in the base portion.As can be understood, these raised portions help to retain and maintainthe raised portions in the tacky layer(s), particularly when only thelower-most layer(s) remain in the floor mat. However, it is not requiredthat the base portion be formed with raised portions in practicing thepresent invention. The layers may be formed with raised portions whetheror not the base portion includes complementary raised portions.

[0097] In another alternative embodiment for a tacky portion, the tackyportion could also include a water dissipating capability. The tackyportion could be comprised of a hydrophobic porous structure which wouldassist in dissipating water from the surface of the tacky portion.

[0098]FIGS. 11 and 12 illustrate alternative embodiments for the floormat of the present invention that provide a water dissipating capabilityfor the tacky portion. As will be discussed, the embodiment of FIG. 11also helps to prevent a person from slipping on a potentially wet tackyportion.

[0099]FIG. 11 illustrates an embodiment for tacky portion 300 where thetacky layers 301 and 302 of the tacky portion define a plurality ofapertures 300C therein. The apertures of each layer are aligned with theapertures of each other layer. Thus, because of the aligned apertures inthe layers, the tacky portion is able to drain surface water from thetop-most surface of the tacky portion, or from the soles of a person'sshoes that is standing on the tacky portion, through the apertures andto the base portion, within which the layers may be positioned. The baseportion, as discussed previously, may include a water dissipationcomponent and/or a water absorbing component which would move and/orabsorb the surface water drained from the tacky portion through theapertures.

[0100] The apertures would also provide for helping to prevent slippingon a wet surface of the layers, not only by draining surface water fromthe surface, but by also providing for enhanced frictional contactbetween the shoes of the person stepping on the layer and the layeritself. The apertures provide for discontinuities in the surface of thelayer which would enhance the frictional contact between the person'sshoes and the layer. The edges of the surface of the layer which definethe apertures would provide for this enhanced contact. The person'sshoes would engage with the edges, thus enhancing frictional contact forthe shoes. Additionally, the apertures would act as a suction on thebottoms of the person's shoes, e.g., like suction cups. This suctioncaused by the apertures on the person's shoes would also help to preventslippage on the surface of the layer.

[0101]FIG. 12 illustrates another embodiment for the floor mat of thepresent invention that also provides a water dissipating capability forthe tacky portion. As can be seen, tacky portion 300 includes layers 301and 302. Base portion 200 defines a recess where layers 301 and 302 aredisposed within the recess. A surface of the base portion that defines abottom of the recess includes a raised portion 200C at or near a centerposition within the recess. Thus, the raised portion 200C of the baseportion forms a raised portion in each of the layers. As can beunderstood, the raised portion formed in the layers acts to dissipatesurface water on the layers from the layers. The surface water willdrain off of the layers under the force of gravity due to the raisedportion.

[0102] Again, any number of layers may be included in tacky portion 300in the embodiments of FIGS. 11 and 12.

[0103] It is also contemplated that a water absorbing powder, such as atalcum powder, could be provided in the present invention. The powdercould either be integrated into the floor mat or be separatelyassociated with the floor mat. The talcum powder would remove moisturefrom the soles of a person's shoes when the person stepped into thepowder and the tacky insert portion could then remove the powder fromthe person's soles, in addition to any dirt on the soles, when theperson next steps on the tacky insert portion.

[0104] The present invention also provides an apparatus and method fordetermining when the tacky portion, or a layer in the tacky portion,should be removed for cleaning. Since the tacky portion assists inremoving dirt from the soles of the person's shoes that steps on thetacky portion, the tacky portion, or a layer thereof, will become dirtyafter some number of persons step on the it, assuming that anyparticular person's shoes are not exceptionally dirty. Therefore, itwould be desirable to assist a person in deciding when to remove a dirtytacky portion for cleaning. Again, as discussed above, thisdetermination can be made after a certain number of persons step on themat. Thus, an embodiment of the present invention as illustrated in FIG.13 includes a sensor system 700 that detects the presence of a person onthe floor mat 100. The sensor system 700 may detect the presence of aperson on base portion 200 and/or tacky portion 300. Since it is assumedthat a person who steps on base portion 200 will also step on tackyportion 300, sensing the person's presence on either portion issufficient for practicing the present invention.

[0105] Sensor system 700 includes a sensor 710 and a display device 720,e.g., an LED, coupled to sensor 710 and disposed on mat 100 such that itcan be viewed. A power source, such as a battery, may be included on anunderside of the floor mat. As mentioned above, sensor 710 senses thepresence of a person on mat 100, e.g., in this embodiment on tackyportion 300. The sensor can detect the person's presence by utilizingany of a variety of apparatuses and methods and can include sensing thepressure applied to the mat by the weight of the person standing on themat or by sensing the motion across the surface of the mat by themovements of the person. Thus, pressure sensors and motion detectors maybe utilized in the present invention. Sensor system 700 also determinesthe number of persons that have stepped on the mat 100 by counting thenumber of sensed presences. After the number of presences equals adefined number of presences, a signal is provided to display device 720,e.g., illuminating the LED, which indicates that the tacky portionshould be removed for cleaning. The present invention is not limited toremoving the tacky portion at any particular number of sensed presencesand the number may be adjusted based on the particular environmentalconditions in which the mat is utilized. Of course, as can beunderstood, after the dirty tacky portion or layer is removed and/orcleaned the sensor system can be reset to begin counting the totalnumber of presences on the newly cleaned or exposed layer.

[0106] Alarm device 720 can provide either a visual, audible, orvibratory signal and the present invention is not limited to providingany particular type of signal. For example, a visual signal couldconsist of a light that is illuminated when the floor mat should becleaned and that is not illuminated when the floor mat does not requirecleaning. Alternatively, the light could be continuously illuminated inone of a plurality of different colors, with each color signifying adifferent state of cleanliness for the floor mat. For example, a greenlight could signify that the mat does not need cleaning. A yellow lightcould indicate the mat is reaching a state of dirtiness that will soonrequire cleaning. A red light, which could blink on and off, couldsignify that it is time to clean the floor mat.

[0107] The sensor system of the present invention may be utilized withany of the embodiments disclosed for the cleanable portion, which may ormay not be an insert and may or may not include layers and a tackysurface(s), and the base portion.

[0108] Whereas cleanable portion 300 has been discussed as an insertportion, it is not required that cleanable portion 300 be inserted intofloor mat 100. There exists many alternative possibilities forassociating cleanable portion 300 with floor mat 100. For example,cleanable portion 300 could be placed on top of base portion 200 orcould be positioned adjacent to base portion 200. The present inventionis not limited to inserting any of the embodiments for cleanable portion300 within base portion 200.

[0109] For example, FIG. 14 illustrates a tacky portion 300 and anon-tacky portion 200, which may include a water dissipation component,a water absorbing component, and a cushioning component, as discussedpreviously, that are separable. As can be seen in FIG. 14, tacky portion300 may be bordered within a border 500, which may be water absorbent,water dissipative, and include a cushioning component, and may include aplurality of apertures 342 and treads 344 within it. Tacky portion 300can include any of the embodiments previously discussed. An attachmentlayer 600 is positioned on an underside of both border 500 of tackyportion 300 and non-tacky portion 200. The border 500 and/or non-tackyportion 200 may be releasably attached to attachment layer 600. Thus,through attachment layer 600, border 500, and therefore tacky portion300, and non-tacky portion 200 are releasably attachable to each other.In this manner, it is possible to, for example, position non-tackyportion 200 outside of a person's home on the front porch and tackyportion 300 within the person's home.

[0110] Attachment layer 600 can be any of a variety of materials. Allthat is required is that the attachment layer be able to releasable joinone portion of the floor mat to a second portion of the floor mat. Forexample, a hook and loop fastener assembly, e.g., Velcro®, can be usedwith one portion of the assembly on the attachment layer and the otherportion on the underside of the first portion of the floor mat and thesecond portion of the floor mat. Alternatively, an adhesive can beutilized to releasably join the two portions of the floor mat to theattachment layer. Additionally, snaps, including any type of male/femaleconnector, may be used to join the two portions to the attachment layer.

[0111]FIG. 15 illustrates a first process step in utilizing anembodiment of the floor mat 100 of the present invention. As wasdescribed previously, an embodiment of floor mat 100 includes a baseportion 200 and an insert portion 300. As can be seen in FIG. 15, and aswas also discussed previously, a different graphic display 220 ispresent in the embodiment of FIG. 15 than was illustrated in theembodiment of FIGS. 1 and 2. Thus, FIG. 15 displays a “Hello” messagewith “smiley face” representations in the graphic 220.

[0112] As can be seen in FIG. 15, in utilizing an embodiment of thepresent invention, a user would first step upon base portion 200. Asdiscussed earlier, base portion 200 may include a water dissipatingand/or absorbing component and is thus able to assist in removing anymoisture from the soles of the person's shoes. As was also discussedearlier, because base portion 200, in one embodiment, also includes acushioning component, base portion 200 conforms to the person's soleswhen the person steps upon base portion 200. Whereas not illustrated inFIG. 15, as discussed previously, an antibacterial composition, anantifingal composition, a fragrance, or any other cleaning substance mayalso be associated with floor mat 100 and applied to the soles of theperson's shoes when the person applies pressure to floor mat 100.

[0113] As can be seen in FIG. 16, the second process step in utilizingthe present invention includes the person stepping onto insert portion300 of floor mat 100. As discussed previously, insert portion 300 mayinclude a tacky surface on a top side thereof for assisting in removingdebris from the soles of the person's shoes. Additionally, antibacterialcompositions, antifungal compositions, fragrances, or other cleaningcompositions may also be included within insert portion 300 fordispensing to the soles of the person's shoes.

[0114] After the person steps onto insert portion 300, the user thensteps off of floor mat 100. As described previously, floor mat 100 maybe cleaned after an accumulation of dirt on insert portion 300 by any ofthe methods described previously. Insert portion 300 may be removed frombase portion 200 and cleaned, a layer may be removed from insert portion300 to be cleaned or discarded, or insert portion 300 may be cleanedthrough erosion of insert portion 300. The present invention is notlimited to any particular methodology for cleaning insert portion 300 offloor mat 100.

[0115]FIGS. 17-22 illustrate further alternative embodiments for thefloor mat of the present invention. As can be seen in FIG. 17, in thisembodiment for the floor mat, floor mat 1700 includes a cleanableportion 1710 and a plurality of base portions 1720A-D. As can be seen,cleanable portion 1710 is positioned within one of base portions1720A-D. In this manner, the floor mat 1700 can be customized for aparticular user by interchanging the cleanable portion 1710 with one ofa variety of base portions 1720A-D. The base portions 1720A-D can beformed in any of a variety of physical configurations and can includeany of a variety of themes, graphics, or colors. Thus, a commoncleanable portion 1710 may be utilized with a variety of base portions1720A-D.

[0116]FIGS. 18-20 illustrate another alternative embodiment for a floormat 1800 in accordance with the principles of the present invention. Ascan be seen in FIG. 18, floor mat 1800 also includes a cleanable portion1810 and a base portion 1820. As discussed previously, cleanable portion1810 is received within base portion 1820. In this embodiment, cleanableportion 1810 is comprised of a single sheet 1810A. The single sheet1810A may be tacky on a top-side thereof and may include aperturestherein to receive anti-slip nipples though it, as was also discussedpreviously. The single sheet 1810A, in this embodiment, may be removedand replaced with another sheet when dirty.

[0117]FIG. 19 illustrates that a plurality of sheets 1810B-D, may beattached to each other and rolled into a roll 1830 of sheets. The sheetscan be joined to each other at a perforated joint to provide for ease inseparating a sheet from the roll of sheets. As can be understood, asheet may be separated from the roll of remaining sheets and may be theninserted into base portion 1820.

[0118]FIG. 20 illustrates that the roll of sheets 1830 may be stored ina storage device 1840, such as, for example, by mounting the roll ofsheets 1830 on a cabinet door, which may be located in proximity to thefloor mat. In this manner, replacements sheets are easily organized andstored for use.

[0119] Alternatively, instead of organizing the sheets in a roll andstoring the roll in a cabinet, the sheets could be folder one uponanother such that they form a flat package. The package of sheets couldthen be stored underneath of the floor mat 1800 where individual sheetscould be removed from the package and from under the floor mat, whenneeded, similar to the way a Kleenex® (tissue is dispensed.

[0120]FIG. 21 illustrates another alternative embodiment for a floor matin accordance with the present invention. Floor mat 2100 also includes acleanable/scrapable portion 2110 and a base portion 2120. In thisembodiment, cleanable portion 2110 is formed, as discussed previously inthis application, as a single structural member from a material which istacky in composition throughout the entire cross-section of thematerial. As was also discussed previously, by forming portion 2110 froma uniform, tacky material, the portion 2110 does not necessarily have tobe removed from the base portion 2120 to be cleaned. However, in theembodiment previously discussed, the cleanable portion 2110 could becleaned by eroding the top surface of the insert portion as a result ofuse of the insert portion. In the embodiment of FIG. 21, the cleanableportion is cleaned by scraping off a top surface of approximately 2-3microns from the cleanable portion 2110 by utilizing a scraper 2130.

[0121] Scraper 2130 can include any of a variety of structures, however,all that is required is that the scraper be capable of removing a topsurface from cleanable portion 2110. For example, any type of scrapingsurface can be utilized in scraper 2130, such as, for example, a dullknife, a razor, or a plane.

[0122] Scraper 2130 is movable on tracks 2140, 2145. Tracks 2140, 2145are adjacent to cleanable portion 2110 and base portion 2120. Scraper2130 may include wheels or other structures, e.g., pins, which arereceived within complementary structures, e.g., grooves, in tracks 2140,2145. Thus, scraper 2130 is movable across cleanable portion 2110 ontracks 2140, 2145. The scraper 2130 may only include a scraping surfaceon the portion of scraper 2130 that is movable across cleanable portion2110. Additionally, it is not required that two tracks be utilized. Thescraper could be movable within a single track.

[0123] Scraper 2130 may be moved by any of a variety of methods,including using the foot of a user to engage with the scraper to movethe scraper on the tracks.

[0124] Floor mat 2100 also includes a catch basin 2150 that may beincluded at one or both ends of tracks 2140, 2145. Catch basin(s) 2150includes a recess into which is deposited the shavings from cleanableportion 2110 after scraper 2130 scrapes the cleanable portion. Scraper2130 moves the shavings off of the cleanable portion and into the catchbasin 2150. The shavings from the cleanable portion deposited into thecatch basin may be removed from the catch basin in any of a variety ofways, including, for example, by vacuuming the shavings from the catchbasin or removing a detachable catch basin, throwing away the contentsfrom the catch basin, and reinstalling the catch basin.

[0125] As can be understood, as the cleanable portion is shaved, thescraper is commensurately lowered on tracks 2140, 2145 such that thesurface of the scraper that engages with the cleanable portion remainsengaged with the cleanable portion. As such, for example, the scrapermay be mounted on a ratchet mechanism such that, as the scraper is movedacross a complete width of the floor mat, the scraper actuates theratchet such that the ratchet lowers the scraper. Alternatively, thescraper could remain in the same relative position with respect to thetracks and the tracks could be ratcheted lower with respect to the baseportion and cleanable portion. Additionally, the blade surface of thescraper could be lowered with respect to the scraper's structure suchthat the blade is moved relative to the cleanable portion and the baseportion but the scraper remains in the same relative position withrespect to the tracks and the cleanable portion and the base portion.

[0126] Additionally, it is not required that a base portion be utilizedin the embodiment for floor mat 2100. The cleanable portion alone can beutilized with the tracks adjacent the cleanable portion and the scrapermovable on the tracks. A catch basin(s) could still be utilized. Assuch, FIG. 22 illustrates an embodiment for floor mat 2200 that includesa cleanable portion 2210 without use of a base portion. Cleanableportion 2210 is adjacent to tracks 2240, 2245. Scraper 2230 is movableon tracks 2240, 2245. A catch basin 2250 may be included at one or bothends of tracks 2240, 2245.

[0127] Thus, as described previously, the floor mat of the presentinvention includes features as described below. It should be noted thatthe below-listed features are not all-inclusive of the features of thefloor mat of the present invention. This specification in its entiretydiscloses all of the features of the floor mat of the present invention.

[0128] As described previously, in an embodiment, the floor mat includesa tacky surface having a top exposed surface with a surface area and asubstantially non-paper anti-slip component disposed within the surfacearea of the top exposed surface of the tacky surface to prevent slippingon the tacky surface when wet. Thus, the anti-slip component is inoperable association with the top exposed surface of the tacky surfaceto reduce slippage of a person on the top exposed surface who steps onthe top exposed surface when the top exposed surface is wet. Theanti-slip component may be integrally included in the top exposedsurface.

[0129] The anti-slip component may include a plurality of channels ascan be seen in FIG. 5 which are comprised of a non-tacky material wherethe plurality of channels is extendible from the top surface of thetacky surface in response to a person stepping on the tacky surface.Alternatively, the floor mat may include an anti-slip component that isextendible from the top surface of the tacky surface in the absence of aperson standing on the tacky surface, such as the treads describedpreviously. Thus, the treads may be elongated members that have a lengthextending across the top exposed surface of the tacky surface which issubstantially greater than a height that the treads extend above the topexposed surface of the tacky surface.

[0130] Additionally, the anti-slip component may be the aperturesillustrated in FIG. 11.

[0131] The various embodiments for an anti-slip component may becomprised of a non-tacky material, e.g., non-tacky members, and a waterresistant material. Thus, the anti-slip components may be waterresistant. The anti-slip components may also be comprised of a materialsuch that they remain functional to prevent slipping on the tackysurface after a plurality of uses. As such, the anti-slip component maybe comprised of a sufficiently rigid material such that a configurationof the anti-slip component is substantially maintained after beingstepped on a plurality of times by a person and may be comprised of amaterial having a composition which is substantially maintained afterhaving been stepped on a plurality of times by the person.

[0132] As was also described previously, in an embodiment, the floor matincludes a base portion having a non-tacky exposed top surface area 250or contacting the soles of a person's shoes thereon and a tacky portionassociated with the non-tacky exposed top surface area of the baseportion and having a tacky exposed top surface area 350 for contactingthe soles of the shoes thereon. As can be seen at least in FIG. 1, thebase portion non-tacky exposed top surface area 250 is at least as largeas the tacky portion tacky exposed top surface area 350.

[0133] The floor mat's base portion may include a cushioning componentsuch that when the person's shoes applies pressure to the base portionand the tacky portion, both the base portion and the tacky portionconform to a topography of a bottom of the person's shoes. The tackyportion may also include a tacky surface on a bottom side of the tackyportion.

[0134] In various embodiments, the base portion may circumscribe thetacky portion, as can be seen in FIG. 1, or may be located adjacent tothe tacky portion, as can be seen in FIG. 14.

[0135] As can also be seen in at least FIG. 1, the floor mat has a baseportion that has a continuous non-tacky exposed top surface area 250 forcontacting the soles of a person's shoes thereon and a tacky portionhaving a tacky exposed top surface area 350 for contacting the soles ofthe shoes thereon. As can be seen also in FIGS. 15 and 16, the non-tackyexposed top surface area of the base portion and the tacky exposed topsurface area of the tacky portion are both of a size such that an entiresole of an adult-sized shoe is receivable thereon. The continuousnon-tacky exposed top surface area 250 of the base portion has a firstside area 252 disposed on a first side 352 of the tacky exposed topsurface area of the tacky portion and a second side area 254 disposed ona second, opposing side 354 of the tacky exposed top surface area of thetacky portion. The first side area of the continuous non-tacky exposedtop surface area of the base portion is larger than the second side areaof the continuous non-tacky exposed top surface area of the baseportion.

[0136] In the following discussion, it is to be understood that thefloor mat “base portion,” referred to in the foregoing primarily by thereference number 200, but also referred to in alternative embodiments byreference number 1820, for example, comprises at least a base portionunderlayer and a non-tacky layer. At least a section of the non-tackylayer may be separable from the base portion underlayer. It should beunderstood that the base portion could be a single layer or multiplelayers so long as it cooperates properly with the tacky insert.

[0137] In consideration of the above, FIG. 23 is an exploded view of afloor mat according to yet another embodiment of the present invention.The floor mat includes a base portion underlayer 2300 formed as asubstantially planar sheet of material of a pre-determined thickness andhaving a raised border 2303 circumscribing the planar sheet. The sheetof material includes a substantially planar surface 2302. The materialmay be a pliable, durable, water-resistant material such as vinyl,plastic or rubber, formed into the desired configuration by, forexample, compression molding, injection molding, thermoforming, or otherprocesses.

[0138] The base portion underlayer includes an area 2301 configured toreceive a tacky insert 2306. The area 2301 may be bordered by a rim 2308of material higher than the surface 2302. When placed within the area,the tacky insert may abut a section of the raised border 2303, so thatthe rim and the border cooperate in retaining the tacky insert withinthe base portion underlayer. The base portion underlayer includesanti-slip components 2309 in the area 2301. The anti-slip componentsextend through apertures 2307 in the tacky insert and also help tosecure it in place on the base portion underlayer.

[0139] Further shown in FIG. 23 is a non-tacky layer 2304 of apre-determined thickness configured to be received into base portionunderlayer 2300 within the raised border 2303. A portion of thenon-tacky layer may be permanently bonded to the base portionunderlayer. The raised border 2303 may be formed as a “cove molding,”wherein, as shown in cross-sectional view 23-23, beginning at an outeredge 2303.1, the material of the border slopes upwardly and inwardly. Aninner edge 2303.2, i.e., a difference in height between the planarsurface 2302 and a part of the raised border may be substantially equalto a thickness of the non-tacky layer 2304. The non-tacky layer has acut-out area 2305 that conforms to the shape of the tacky insert, sothat when the non-tacky layer and the base portion underlayer are puttogether, edges of the cut-out area abut or are adjacent to the rim2308, and the upper surface of the non-tacky layer is higher than thesurface of the area 2301 for receiving the tacky insert. Thus, the baseportion underlayer together with the non-tacky layer form a base portionhaving a recess configured to receive the tacky insert.

[0140] The non-tacky layer 2304 may have properties of components of thebase portion

[0141]200 described earlier. For example, the non-tacky layer 2304 mayhave any combination of water-absorbing properties, water-dissipatingproperties, water-wicking properties, cushioning properties,antibacterial properties, antifungal properties, a fragrance, graphicsand the like as described above in connection with base portion 200. Thenon-tacky layer may, for example, be a carpet. The area of a top surfaceof the non-tacky layer may be at least as large as the area of a topsurface of the tacky insert. The areas of the top surfaces of thenon-tacky layer and the tacky insert may be respectively of a size suchthat an entire sole of an adult-sized shoe is receivable thereon.

[0142] As discussed above, the tacky insert 2306 may comprise aplurality of separable layers. The layers may comprise a pliable,flexible material such as a polyethylene, bi-axially orientedpolypropylene or polyester film coated with a pressure-sensitiveadhesive to provide tackiness. A user of the floor mat may discard aninsert layer which has become too soiled to effectively clean shoes, toexpose a fresh layer underneath. To facilitate removal of a soiledlayer, at least a section of the non-tacky layer 2304 may be separablefrom the base portion to expose a remove tab 2400 of a layer of thetacky insert, as shown in FIG. 24A. The remove tab 2400 facilitates easyremoval of a layer of the tacky insert by enabling a user to grasp theremove tab and thereby apply a separating force to the layer. The removetab 2400 could be formed of the same material as the tacky insert duringa die-cutting process discussed in greater detail below, but without anyadhesive, to enable easy handling. The remove tab could alternatively beformed from a different material and fastened to the tacky insert. Arecess 2401 may be formed in the base portion underlayer to accommodatethe remove tab or tabs.

[0143] A pull tab 2402, for example in the form of a loop of fabric, maybe provided on an edge of the non-tacky layer to enable a user toseparate a section of the non-tacky layer from the base portionunderlayer. The separable section of the non-tacky layer could besecured to the base portion underlayer by readily-separable fasteners,for example, snap fasteners as shown in FIG. 24A, when in normal use. InFIG. 24A, the pull tab 2402 includes a receptacle component 2403 of thesnap fastener, while the base portion underlayer includes a mated malecomponent 2404. While the floor mat is in normal use, the non-tackylayer would lie flat on the base portion underlayer 2300, bringing thetwo snap fastener components into locking engagement, securing theseparable section of the non-tacky layer to the base portion underlayerand concealing the remove tab or tabs 2400 to give the floor mat a moreaesthetically pleasing appearance.

[0144] In an alternative embodiment as shown in FIG. 24B, the fastenerscould be hook-and-loop fasteners such as VELCRO® and the like. In FIG.24B, a VELCRO® strip 2405 is shown attached to an underside of thenon-tacky layer 2304, and a mating VELCRO® strip 2406 is shown attachedto the planar surface 2302 of the base portion underlayer 2300. Whilethe floor mat is in normal use, the non-tacky layer would lie flat onthe base portion underlayer 2300, bringing the two VELCRO® strips intocontact, securing the separable section of the non-tacky layer to thebase portion underlayer and concealing the remove tab or tabs 2400.

[0145] Alternatively to the remove tab 2400 extending into the area ofthe base portion underlayer covered by the non-tacky layer so that theremove tab is hidden, the remove tab could extend into the area 2301 ofthe tacky insert, as shown in FIG. 24C. The tabs could be numbered, toindicate to a user, for example, how many tacky insert layers have beenused.

[0146]FIGS. 24D and 24E show side elevation views of remove tabs 2400corresponding to the case when the tacky insert comprises a plurality oflayers. As shown in FIG. 24D, the remove tabs could be layered in agraduated fashion, such that an edge of an upper tab extends beyond anedge of a tab below it. Such an arrangement could enable easiermanipulation of a remove tab. Alternatively, the tabs could beco-extensive as shown in FIG. 24E.

[0147]FIG. 25 shows an embodiment of the floor mat wherein a baseportion underlayer 2500 is joined to a non-tacky layer 2504 and issubstantially co-extensive with the non-tacky layer. That is, in theembodiment of FIG. 25, the base portion underlayer does not have araised border as in the embodiment of FIG. 23. Rather, edges of the baseportion underlayer 2500 and the non-tacky layer 2504 are substantiallyin alignment. The base portion underlayer has an area 2501 configured toreceive a tacky insert.

[0148] At least a section of the non-tacky layer 2504 is separable fromthe base portion underlayer, as shown in FIG. 25. The non-tacky layerincludes fasteners 2510, 2511 on an underside thereof, for connecting tofasteners 2507 and 2508, respectively, on the base portion underlayer.The fasteners could be readily-separable fasteners such as VELCRO®(strips. The separable section of the non-tacky layer 2504 has a cut-outarea 2505 with edges configured to frame a top surface area of a tackyinsert 2506. The cut-out area 2505 is sized to be smaller than the topsurface area of the tacky insert, so that when the separable section ofthe non-tacky layer is laid flush with the base portion underlayer,edges of the tacky insert placed into the base portion underlayer extendbeyond edges of the cut-out area. The area of the tacky insert framed byedges of the cut-out area 2505 may be of a size such that an entire soleof an adult-sized shoe is receivable thereon. Thus, the cut-out areaprovides access to the tacky insert for cleaning shoes, while alsohelping to secure the tacky insert within the base portion underlayer.Separating the non-tacky layer from the base portion underlayer wouldenable easier insertion of the tacky insert. Alignment marks 2512bordering area 2501 help a user to position a tacky insert correctly onthe base portion underlayer so that apertures in the tacky insert engagethe anti-slip components 2509. The tacky insert could have a uniformshape, such as a rectangular shape for easy manufacture and storage,while the cut-out area could have any desired shape, allowing a user toselect a shape of the exposed portion of the tacky insert which isaesthetically pleasing to him or her. The shape could be a keystoneshape, for example.

[0149] The areas 2301 or 2501 (of the embodiments of FIGS. 23 and 25,respectively) of the base portion underlayers configured to receive thetacky insert could be provided with a “background” layer having apattern or color grain designed to be aesthetically coordinated with thenon-tacky insert. For example, if the non-tacky layer was a carpet ofsome selected color and/or pattern, the background layer could beselected to match the color and pattern of the carpet. The backgroundlayer could be permanently bonded to the base portion underlayer, and insuch a case the tacky insert would be transparent to show the backgroundlayer.

[0150] Alternatively, some or all or the layers of the tacky insertcould have a pattern and/or color grain. These could be used instead ofa permanent background layer, or could be used to temporarily cover apermanent background layer. Or, the base layer of a plurality of layersof the tacky insert could have a pattern or color grain, and the rest ofthe layers would be transparent to show the base layer. The patternand/or color grain of a layer or layers of a tacky insert could becustomized as desired, for example, to reflect a particular holidayseason.

[0151] If the tacky insert comprises a plurality of layers, a base layercould have an adhesive undersurface to secure the layers to the baseportion underlayer. The tacky insert could also have such an adhesiveundersurface if it consisted only of a single layer. In either case, theundersurface adhesive would be strong enough to ensure that the insertwas not easily dislodged from the floor mat when used to clean shoes,but not so strong that the insert would be difficult to remove bydeliberate manipulation and application of force for that purpose.

[0152] Similarly, whether in the form of a single layer or a pluralityof layers, the tacky insert may further be provided with a releaselayer, as shown in FIG. 26A. FIG. 26A shows side elevation views of twopossible embodiments of a tacky insert 2306 comprising a plurality oflayers (the dimensions of the layers are exaggerated for purposes ofillustration). The embodiments have a base layer 2600 with two differenttypes of adhesive undersurface with a release layer. In one embodiment,the adhesive undersurface comprises at least two strips of adhesive2601, each with a release layer 2602. At least a portion of theundersurface of the base layer bearing the strips is not adhesive. Inthe other embodiment, the adhesive undersurface 2603 and its releaselayer 2604 are co-extensive with the base layer.

[0153] The release layer functions along lines similar to that of apeel-off sticker, Band-Aid® or the like. The release layer covers theadhesive undersurface of the tacky insert. The release layer has anon-adhesive outer surface for easy handling, and an inner surface forcontacting the tacky insert undersurface. The inner surface of therelease layer is easily separable from the tacky insert undersurfacewhen a user wants to install the tacky insert in the base portion.

[0154]FIGS. 26B-26D illustrate one possible embodiment of the inventionfor simplifying the placing of a tacky insert with an adhesiveundersurface and a release layer into the base portion. As shown in FIG.26B, the base portion underlayer 2300 is provided with alignmentprotrusions 2605 on a section of the raised border extending along thearea 2301 for receiving the tacky insert. The location of the alignmentprotrusions is arbitrary and could depend on the shape of the tackyinsert. The alignment protrusions could alternatively be located, forexample, on sides 2607 or an end 2608 of the area 2301.

[0155] A tacky insert 2306 is provided with notches 2609 spaced so as tocorrespond to protrusions 2605. As shown in FIG. 26C, a user may peeloff the release layer (not shown), then bring the notches of the tackyinsert into engagement with the protrusions of the base portionunderlayer to align and stabilize the tacky insert in preparation forlowering the tacky insert to bring it into engagement with the baseportion underlayer. Then, perhaps applying the tacky insert in a“rolling” motion, the user brings the undersurface of the tacky insertinto contact with the base portion underlayer as shown in FIG. 26D,possibly applying pressure to ensure adequate adhesion.

[0156] According to another embodiment not illustrated, the releaselayer could be separated into two or more sections. Apertures alignedwith the apertures of the tacky insert would also be formed in therelease layer. To install a tacky insert with such a release layer, auser could align the apertures with the anti-slip components and placethe tacky insert into the base portion underlayer with the release layerstill on. Then, because the tacky insert is flexible, the user couldlift and bend a portion of the tacky insert away from the base portionunderlayer. While holding the remaining portion in place, the user couldremove a section of the release layer from the lifted portion of thetacky insert, lower the uncovered portion to the base portionunderlayer, and apply pressure to adhere the uncovered portion to thebase portion underlayer. Then, the user could lift and bend theremaining, un-adhered portion of the tacky insert, remove the releaselayer, and adhere the remaining portion of the tacky insert to the baseportion underlayer.

[0157] As noted above, a tacky insert could comprise a plurality ofseparable layers. FIG. 27A is a side elevation view illustrating onepossible sequence of layers in a tacky insert. In the example of FIG.27A, the tacky insert has 12 layers, but clearly a tacky insert havingmore or fewer layers is readily contemplated. In FIG. 27A, each oflayers 1-12 comprises at least an adhesive layer and a film layer. Theadhesive layer provides the tacky surface of the tacky insert forcleaning shoes as described above, when exposed for use. The film is amedium for the adhesive layer.

[0158] In addition to adhesive and film layers, the top layer 1 and baselayer 12 each include a release layer. The release layers have anon-tacky outer surface (i.e., the surfaces opposite the surfaces incontact with an adhesive layer) to enable a group of layers to be easilypackaged, unpackaged and handled by a user. The release layers areeasily separated from the adhesive layer when a user needs to install atacky insert into a base portion of a floor mat.

[0159] To install a multi-layer tacky insert as shown in FIG. 27A, auser would peel away the base release layer from layer 12 to expose thebase layer adhesive, then install the tacky insert in the base portionof the floor mat. The tacky insert could have notches, or a base releaselayer of two sections, to facilitate installation of the tacky insertinto the base portion as described above. The base layer adhesive wouldsecure the tacky insert within the base portion. The film of the baselayer 12 or other layers could have a background pattern or color grainas described above.

[0160] The user would then remove the top release layer to expose theadhesive surface of the first layer for use. After the first layerbecame soiled by use, the user would remove the first layer to exposethe adhesive surface of the second layer, and begin using the secondlayer. The bond between the adhesive surface of one layer and the filmof the layer above it would be strong enough to ensure that the upperlayer was not easily dislodged from the lower layer or layers when usedto clean shoes, but not so strong that the upper layer would bedifficult to remove by deliberate manipulation and application of forcefor that purpose. When all the layers of the insert were used up, theuser could remove the base layer and install a new insert.

[0161]FIG. 27B illustrates an alternative embodiment of a layer of atacky insert. As shown in FIG. 27B, a layer of a tacky insert couldcomprise adhesive 2700 interspersed with an integral anti-slip material2701, overlaid on a film layer. The anti-slip material could extend in astrip across the layer, as shown in FIG. 27C. This integral anti-slipmaterial could be used to perform an anti-slip function in substitutionfor anti-slip components of the base mat underlayer which are receivedby apertures in the tacky insert. Alternatively, both integral anti-slipmaterial and anti-slip components received in apertures of the tackyinsert could be used to provide an anti-slip function.

[0162] A method and apparatus for manufacturing a tacky insertcomprising a plurality of layers will now be described. A basic materialfor forming the layers could be a low-density polyethylene, bi-axiallyoriented polypropylene or polyester film manufactured and distributed inbulk quantities in units of continuous rolls. The basic material couldalso be provided in the form of individual sheets. Typically, film isfed from the rolls and sent through a series of mechanized and automatedlayering processes involving the application of adhesive to provide atacky surface, the application of release layers to facilitate packagingand handling, and the cutting of layers into the desired shape.

[0163] Referring now to FIG. 28, the process for forming tacky insertsincludes forming an upper adhesive layer on a film, as shown in block2800. The upper adhesive layer can be formed by known processes, forexample, using a reverse roll coater machine or a gravure coater machinein a roll-to-roll process. The film with an upper adhesive layerconstitutes a standard layer material for layers of the tacky insert,which is included in all layers subsequently formed. Then, using alaminator, a portion of the standard layer material is laminated with atop layer release film to form a top layer material for forming a toplayer of an insert, as shown in block 2801. This top layer correspondsto layer 1 as shown in FIG. 27A.

[0164] A base layer material for forming a base layer of an insert isformed from a portion of the standard layer material by using a reverseroll coater or gravure coater, for example, to add a base adhesive layerto the side of the film opposite the side with the upper adhesive, andusing a laminator to laminate the base adhesive layer with a base layerrelease film, as shown in block 2802. This base layer corresponds tolayer 12 as shown in FIG. 27A.

[0165] The constituent standard layer, top layer and base layermaterials of the tacky insert are then subjected to further processingby alternative methods according to the invention to produce tackyinserts, as illustrated in FIGS. 29A, 29B and 29C, respectively, anddiscussed in greater detail below.

[0166] According to a known method called “multiple lay-up” (notillustrated), all the layers may first be brought together intomulti-layered laminate which is subsequently cut into tacky insertshapes. However, this process suffers from the disadvantage thatundesirable bonding of the cut layers can occur at the edges thereof.

[0167] Thus, to avoid the problem of edge bonding, the tacky inserts maybe formed in a process involving a rotary die cutter according to atleast three alternative embodiments of the invention. Rotary die cuttersare well-known in the manufacturing arts. However, the use of rotary diecutters in a process to form a multi-layered structure as shown in FIG.27A is not known.

[0168]FIG. 29A shows an apparatus configured to cut tacky inserts usinga rotary die cutter according to the invention. A number (for example,12) of individual rollers 2900 are shown for feeding the top layer,standard layer, and base layer materials, respectively, to a laminator2901 and then to a rotary die cutter 2903. The layers are fed in acontinuous form known as a “web.” A laminator is a known machine whichis configurable to apply a pre-determined amount of pressure and tensionvia rollers to a plurality of webs so as to join webs to each other witha desired bonding strength. For example, the laminator would applysufficient pressure such that, once finished, a tacky insert would noteasily separate into its constituent layers upon casual handling, butnot so much pressure that layers would effectively fuse together and bedifficult to separate by deliberate manipulation and application offorce for that purpose.

[0169] After the layers are joined by the laminator to form a 12-layerweb 2902, they are processed by the rotary die cutter 2903. The rotarydie cutter 2903 cuts a 12-layer tacky insert 2905 of a desired shapefrom the web 2902.

[0170] A more detailed example of a rotary die cutter is shown in FIG.30. A rotary die cutter typically comprises at least two substantiallycylindrical drums 3000 juxtaposed and rotating in opposite directions toeach other. The drums rotate on shafts 3002 driven by gears 3003. Outersurfaces of the drums include engraved knives 3001 outlining a desiredshape to be cut out of a web 3004. A shape on one of the drum surfacesis the mirror image of the shape on the opposing drum surface. In thecase of tacky inserts, the outlined shape could be a keystone shape, forexample, as described above. The drums are aligned and their speed ofrotation is set so that corresponding knives on the respective drumscome into contact during rotation, cutting the desired shape out of theweb material. Alternatively, the engraved knives could be on only onedrum, while the opposing drum had a smooth surface. Typically, astripping device (not shown) is used to separate the cut-out webmaterial from the drums.

[0171]FIG. 29B shows an alternative configuration utilizing a rotary diecutter. In FIG. 29B, the tacky insert shapes are first cut out of thebasic materials for the respective layers, then joined by a laminator toproduce the tacky insert. Top layer material is fed to a top layerrotary die cutter, rotary die cutter #1, which is used to cut out aninsert shape for the top layer. Standard layer material is fed to asecond, single standard layer rotary die cutter, rotary die cutter #2,which is used to cut out insert shapes for the standard layers. In thepresent example, 10 standard layer insert shapes are successively cutout by rotary die cutter #2 and stacked in an intermediate stacker (notshown) prior to being laminated together with the top and base layerinsert shapes. Base layer material is fed to a base layer rotary diecutter, rotary die cutter #3, which is used to cut out an insert shapefor the base layer. Then the top layer, standard layers and base layerinsert shapes are laminated together by laminator 2901 to produce atacky insert 2905.

[0172]FIG. 29C illustrates a configuration wherein the insert shapes arecut out of their respective materials before being laminated together,but wherein each layer of the tacky insert is cut to shape by anindividual rotary die cutter.

[0173]FIGS. 31A-31D show plan views of additional embodiments of a tackyinsert 3100 such as could be formed by the above-described process.FIGS. 31A-31D show a different kind of aperture in the tacky insert forreceiving anti-slip components of the base portion underlayer. Whereas,in the embodiments of earlier-discussed figures, the apertures arerelatively elongated in order to receive elongated, “rib-like” anti-slipcomponents, in FIGS. 31A-31D, apertures 3107 have a substantiallycircular form, for receiving nodular, “bump-like” anti-slip components.The apertures 3107 could have various arbitrary distributions, as shownin the figures. Also, the aperture shapes are not limited to circularshapes but could have arbitrary shapes, such as oval, square,rectangular or triangular shapes.

[0174]FIG. 32A shows a plan view of a nodular anti-slip component 3209of the base portion underlayer. Cross-sectional view 32A-32A shows theanti-slip component 3209 received within a circular aperture 3107 of atacky insert 3106. An upper surface of the anti-slip component extendsbeyond an upper surface of the tacky insert. The anti-slip component3209 is deformable such that it will be deformed downwardly when thepressure of a person's shoe is applied to the anti-slip component,allowing the sole of the shoe to come into contact with the tackysurface of the insert. When the pressure of the shoe is removed, theanti-slip component resumes its original form.

[0175]FIG. 32B shows a plan view of an embodiment of a nodular anti-slipcomponent 3210 having textural features 3211 on an upper surfacethereof, for better slip prevention. Cross-sectional view 32B-32B showsthe anti-slip component 3210 received within a circular aperture 3107 ofa tacky insert 3106. The anti-slip component is deformable and has aspring-like form wherein pressure applied by a shoe causes the anti-slipcomponent 3210 to be compressed at pre-determined bend points 3212,allowing the sole of a shoe to come in contact with the tacky surface ofthe insert. When pressure is removed, the anti-slip component 3210springs back to its original shape.

[0176]FIG. 32C shows a plan view of yet another embodiment of a nodularanti-slip component 3215 which includes textural features 3216 on anupper surface thereof. Cross-sectional view 32C-32C shows the anti-slipcomponent 3215 received within a circular aperture 3107 of a tackyinsert 3106. The textural features 3216 are arranged on a supportportion 3217 of the anti-slip component. The textural features may bemade of a relatively non-deformable material, such as a hard rubber orplastic, while the support portion 3217 may be made of a deformablematerial such as foam rubber, to allow contact with the tacky surface asdescribed above.

[0177] As shown in exploded view 32C′-32C′, the anti-slip component 3215may be separable from the base portion underlayer 3220, to allow theanti-slip component to be replaced when worn. On the other hand, theanti-slip component could be permanently bonded to the base portionunderlayer. An aperture 3225 in the base portion underlayer may becountersunk, to allow for a flush meeting of the anti-slip component anda bottom surface of the base portion underlayer.

[0178]FIG. 32D shows a plan view of yet another embodiment of adeformable nodular anti-slip component 3218 which includes texturalfeatures embodied as grooves 3219 in an upper surface thereof.Cross-sectional view 32D-32D shows the anti-slip component 3218 receivedwithin a circular aperture 3107 of a tacky insert 3106. Breaking up thesurface of the anti-slip component with grooves as shown aidscompressibility and introduces a texture to the anti-slip componentwhich further reduces slipping. FIG. 32E shows an enlarged perspectiveview of anti-slip component 3218.

[0179] Textural features 3211, 3216 and 3219 as discussed above areillustrated by way of example only. Any kind of textural feature whichbreaks up the surface of the nodular anti-slip component is encompassedwithin the scope of the inventive concept disclosed herein. Example ofother kinds of textural features that could be used include bumps,ridges, dimples, raised spirals, automobile-tire-like patterns, randompatterns and the like.

[0180] Returning to FIGS. 31A-31D, a remove tab 3100 is provided on anedge of the tacky insert. As with the remove tabs 2400 described above,the remove tabs 3100 could be formed of the same material as the tackyinsert during a die-cutting process as discussed above, but without anyadhesive, to enable easy handling. The remove tab could alternatively beformed from a different material and fastened to the tacky insert. Theremove tab location is arbitrary. The base portion underlayer could havea recess for receiving the remove tab.

[0181] All of the disclosed embodiments are illustrative of the variousways in which the present invention may be practiced. Additionally, anyof the disclosed embodiments for the components of the floor mat, e.g.,the base portion, the tacky portion, the graphic display, and thus allof the features associated with these components, may be combined in anyembodiment of the present invention and the present invention is notlimited to only the particular combined embodiments disclosed. Otherembodiments can be implemented by those skilled in the art withoutdeparting from the spirit and scope of the present invention.

What is claimed is:
 1. A tacky insert having a top tacky exposed outersurface capable of being walked on and cleaning at least a portion of abottom of a person's shoes, the tacky insert including aperturestherethrough capable of draining water.
 2. The tacky insert of claim 1,wherein said tacky insert is transparent.
 3. The tacky insert of claim1, wherein said tacky insert comprises a plurality of separable layers.4. The tacky insert of claim 1, wherein said tacky insert includeslow-density polyethylene.
 5. The tacky insert of claim 1, wherein saidtacky insert includes bi-axially oriented polypropylene.
 6. The tackyinsert of claim 1, wherein said tacky insert includes polyester.
 7. Thetacky insert of claim 1, wherein said tacky insert includes paper. 8.The tacky insert of claim 1, wherein said tacky insert includes ahydrophilic substance.
 9. The tacky insert of claim 1, wherein saidtacky insert includes a hydrophobic substance.
 10. The tacky insert ofclaim 1, wherein said tacky insert includes a water-dissipatingproperty.
 11. A tacky insert having a tacky top exposed outer surface,wherein said tacky insert is capable of being walked on and cleaning atleast a portion of a bottom of a person's shoes, said tacky top exposedouter surface having apertures capable of draining water, and comprisinga material that is at least partially hydrophilic.
 12. A tacky inserthaving a tacky top exposed outer surface, wherein said tacky insert iscapable of being walked on and cleaning at least a portion of a bottomof a person's shoes, said tacky top exposed outer surface havingapertures capable of dissipating water.